Stabilized vinyl chloride resins containing alkali metal formates or oxalates



2,960,490 Patented Nov. 15,1960

United States Patent ice In the preparation of such plastisol compositions, the various ingredients are mixed and milled together in a 2,960,490 suitable mill for a sufficient period to effect an intimate STABILIiZED VINYL CHLORIDE RESINS suspension of the finely divided particles. The resulting TAINING ALKALI METAL FORMATES 0R 5 mixed material is then deaerated and subjected to suffi- LATES cient heat to fuse the mass into usable plastic products. It

. is generally necessary to heat the plastisol composition to Thomas M. Hinkes, Park Forest, 11]., asslgnor to Victor a temperature of about 325 -350 F. for a sufficient Chemical Works a corpomflon of mum's period to cause fusion throughout the full thickness of the No Drawing Filed June 15, 1955, s 515,7 9 10 resin section. Without the presence of the heat stabilizing 18 Claims- 260-4535) discolored during such heating periods.

Polyvinyl chloride polymers and the various copolymers of vinyl chloride and ,vinyl acetate exemplify the This invention relates to the heat and light Stabilization various resin compounds which are suitable for use in the 0f y Chloride resille; and more Particularly, t0 the e plastisol compositions of this invention. Such resin prolight Stabilization of PlastisOl compositions contamducts are available on the market under such trade names ing a vinyl chloride polymer or copolymer. a Vinylitg," and Germ, etc.

It is Well recognized that the Vinyl ehlol'ide'eohtaihihg Various commercial plasticizers, known to be suitable P y and eopolymers tend to deCOmPOSe Slightly I111- 20 for use with vinyl chloride resins, may be satisfactorily der the influence of heat used in the Preparation of Plastic used in the plastisol compositions herein described. These Objects, and under long Periods of exposure to g to plasticizers include dioctyl phthalate, trioctyl phosphate, cause undesirable discoloration in the finished resin prodtricresyl phosphate, acetyl tributyl citrate, etc. llet- The instability of these Polymers and eopolymers is The compounds which are most suitable for the heat generally believed to he due t0 the decomposition of Vinyl stabilization of the plastisol compositions are the sodium chloride substituents in the resin.

Heretofore, a number of difierent compounds have been proposed for the heat and light stabilization of vinyltype resins, but have not been entirely satisfactory from the standpoint of performance or cost.

It has now been found thatexcellent heat and light stability of chlorine-containing vinyl-type resins may be obtained y the inclusion of small amounts f alkali m l sodium oxalate were milled together in a ball mill to form (i.e., sodium and potassium) oxalates and formates in a homogeneously dispersed mixture. The mixture was the plastic formulation prior to fusion of the mixture in 30 deaerated by subjecting it to vacuum, and then poured into forming the final plastic coating, film or solid object. circular aluminum trays which measured 2 inches in The hot-melt plastic 01 plastisol formulation generally diameter and li inch deep. The trays were placed in a includes a vinyl chloride polymer or a copolymer, a plasfurnace and heated to 350 F. for 15 minutes to comticizer and the stabilizer compound. Vinyl chloride-conpletely fuse and cure the resin disc. The cured discs raining copolymers may be formed by polymerizing vinyl were cooled and compared for discoloration with fused chloride with other copolymerizable materials (i.e., ethylplastisols which did not contain the stabilizer. enically unsaturated monomers), such as vinyl acetate, Table I shows the results of a number of examples using vinyl butyrate, styrene, alkyl acrylates and methacrylates, several combinations of resins, plasticizers and stabilizing acrylic nitriles and the like. If desired, a variety of pigagents. These results show that the sodium and potassium ments and fillers may be included in the formulation. oxalates and formates and mixtures of these compounds Plastisol compositions are known in the art as a type give a marked improvement in heat stability over the of dispersion in which the proportion of plasticizer is high control plastisol composition.

TABLE I and potassium formates and oxalates and mixtures of these compounds. While the ordinary technical grade compounds are quite suitable, it is generally preferredto employ the relatively pure salts.

In formulating a typical plastisol composition, 150 parts by weight of polyvinyl chloride resin, 150 parts by weight of dioctyl phthalate plasticizer, and 9 parts by weight Formulations (parts by weight) i Plastisol Resin Components Control Geon 121 l Vinylite QYNV Resin 1 Vinylite VYNV Resin 1 Vinylite VYNS Resin 1 Vinylite VYHH Resin L-.- Di 2-ethylhexyl phthalate (Flexol DOP) Plasticizer Acetyl tributyl citrate plasticizer Tricresyl phosphate plasticizen Sodium oxalate stabilizer Sodium formate stabilizer. Potassium oxalate stabilizen Potassium iormate stabilizer. Commercial stabilizer (barium stearate). Commercial stabilizer (lead stearate) Color (after heating 15 min. at 350 C.).

l Vinylite QYNV is a commercial polyvinyl chloride resin. Vinylite VYNV is a commercial 95% vinyl chloride-5%vinyl acetate resin. Vinyllto VYNS is a commercial 88-90% vinyl chloride-1210% vinyl acetate resin. Vinylite VYHH is a commercial -88% vinyl chloride1512% vinylacetate resin. (icon 121 is a commercial polyvinyl cholride resin.

2 G=Good (very little or no discoloration). F=Fair (noticeable discoloration). P=Poor (dark red or yellow color). enough to be the sole dispersion medium giving a liquid In the examples shown, the proportion of plasticizer or paste composition which may be used for moldings or used was equal to the weight of the vinyl chloride-containcoatings'without the presence of a volatile component. ing resin. Such proportions are not critical but may be agent, the vinyl chloride-containing resins become badly v varied according to the characteristics desired in the final plastic product. For thick or massablc plastic products, the amount of plasticizer might well be reduced to less than half of the disclosed amount. Such variation in the amount of plasticizer does not materially affect the heat stabilizing effect on the resin component.

In the production of plastic objects from my plastisol compositions, it is possible to control the clarity of the plastic by selection of the stabilizing salt or mixtures thereof together with other additives such as pigments and filler or combinations with other stabilizing agents. For example, a mixture of sodium formate and sodium oxalate gave a clear plastic whereas either alone would produce a translucent plastic. A pure sodium oxalate with a small amount of aluminum hydroxide produced an opaque plastic. However, in all such cases the improvement in heat stability was not adversely affected.

In order to more accurately point out the heat stability elfect on the new plastisol compositions, a series oftest discs were made up with various amounts of sodium formate and sodium oxalate as stabilizing agents. These were heated at 350 F. for 15 minutes and evaluated by the relative change in color. For color evaluation a numerical scale was devised as follows:

Numerical color scale Color Number Description No color (water-white).

Very pale (amber, red, yellow or any other hue). Pale (amber, red, yellow or any other hue). Light (amber red, yellow or any other hue). Medium (amber, red, yellow or any other hue). Dark (amber, red, yellow or any, other hue).

TABLE II Piastisol color No. alter 15 minutes at 350 F.

Amount of Stabilizer (pts. by wt.)

Control (no stabilizer). 0.5 sodium oxalate.

12.0 sodium oxalate 4.0 sodium ior 6.0 sodium ior 0.0 sodium iormate 12.0 sodium iorrnnte The results shown in Table II indicate that the maximum stabilization was obtained with the use of about 6 parts of sodium oxalate (about 4.0% based on the weight of the resin), or about 9.0 to 12 parts of sodium formate (about 6.0-8.0% based on weight of resin). However, a markedly improved color stability was obtained with the use of as little as 0.5 part of sodium oxalate per 150 parts of the polyvinyl chloride resin in the plastic product.

Similar examples show that with plastisols containing 150 parts polyvinyl chloride and 150 parts of tricresyl phosphate plasticizer without stabilizer and with 4 parts of sodium oxalate, the color number comparison was 4 and 3 respectively. With acetyl tributyl citrate as the plasticizer, the color number comparison was 2.5 and 1.0 respectively. The use of other suitable plasitcizers shows similar improved color stability of the plastisol product resulting from the use of the formate and oxalate stabilizing salts.

A comparison was made of several plastisol composi- 4 tions using various vinyl chloride-containing resins with equal amounts of di-Z-ethylhexyl phthalate plasticizer and with and without. sodium oxalate as the stabilizer in amount equal to 2.7% of the resin component. Table Iiil shows the color numbers resulting from the heat fusion of the plastisols at 350 F. for 15 minutes.

TABLE III Plastisol Weight Color Resin Used (Expressed in Wt. percent) percent of Number Sodium aft. 15 Min Oxalate at 350 F Used Polyvinyl chloride N one 3 Do 2. 7 1 Vinyl chloride, vinyl acetate, 5% Ngne] o Virus chloride, 88-90% vinyl acetate, 12-10%. Nan

These results illustrate the improved heat stability of several typical plastisol compositions containing vinyl chloride polymers and copolymers of vinyl chloride with various amounts of vinyl acetate.

Similar improved heat stability was obtained with plastisol compositions containing pigments and fillers which may be added to vary the appearance of the finished plastic product.

A wide variety of vinyl chloride-containing plastisol formulations may be produced in accordance with the present invention which in part comprises the discovery that the heat stability of the vinyl chloride component is greatly improved by combination with a small proportion of a sodium or potassium formate or oxalate or mixtures of such salts. The ratio of the stabilizing formate or oxalate salt to the amount of vinyl chloride in the plastisol composition may be varied from about 0.33% to about 6.0% (e.g., 0.5 to 9.0 parts by weight stabilizer per parts of resin). Somewhat higher amounts may be used without detrimental effect, but do not essentially further improve the heat stabilizing effect.

The following plastisol formulations were milled and deaerated in order to illustrate the light stability induced by my stabilizer. Test specimens were cured in the oven for the optimum time of 15 minutes at 350 F.

Formulation Plastisol Vinylite Flexol Sodium QYN V I DOP I Oxalate (parts by weight) Control 150 150 Stabilized 150 150 4 Plastisol color after exposure to ultraviolet light Plastisol 0 Hours 144 Hours 864 Hours Control 3 1 3 Stabilized". 1 0 o This tabulation indicates that a plastisol formulation containing about 2.7% sodium oxalate, percent based on the weight of resin, greatly improves the light stability of the plastic. The sodium oxalate stabilized formulation was exposed to 864 hours of ultraviolet light with no observable discoloration, whereas the control formulation exposed for the same time interval was noticeably colored.

Vinyl chloride-containing resins appear to possess their most efiective or desirable overall heat and light stability properties when about 4 parts by weight of sodium or potassium formate, oxalate or mixtures of said salts are incorporated with about 150 parts by weight of the vinyl chloride-containing polymer or copolymer. However, satisfactory overall stability is obtained when as low as about 2 parts by weight of the oxalate, formate or mixtures thereof are incorporated with about 150 parts by weight of vinyl chloride-containing polymer or copolymer.

The term vinyl chloride-containing resin refers to a resin containing a vinyl chloride polymer or copolymer.

The foregoing detailed description has been given for clearness of understanding only and no unnecessary limitations should be understood therefrom as modifications will be obvious to those skilled in the art.

I claim:

1. A plastisol resin composition free of stearates and inorganic peroxides and having a stabilizer, which consists essentially of a nonstearate plasticizer, a vinyl chloride resin-from the group of polyvinyl chloride and vinyl chloride copolymers, said plastisol resin composition containing a'stabilizing amount of a'nonstearate stabilizing agent of the group consisting of alkali metal formate, alkali metal oxalate and admixtures thereof, said stabilizing agent being free of inorganic peroxides.

2. The composition set forth in claim 1 wherein the vinyl chloride containing resin is a copolymer of vinyl chloride and vinyl acetate.

3. The composition set forth in claim 1 wherein the weight proportion of vinyl chloride is at least about 85% of the copolymer.

4. The composition of claim 1 wherein the stabilizing agent contains sodium formate.

5. The composition of claim 1 wherein the stabilizing agent contains sodium oxalate.

6. The composition of claim 1 wherein the stabilizing agent contains potassium formate.

} 7. The composition of claim 1 wherein the stabilizing agent contains potassium oxalate.

8. The composition set forth in claim 1 wherein-the plastisol resin composition contains at least about 2 parts by weight of the stabilizing agent for about every 150 parts by weight of the vinyl chloride-containing resin.

9. The composition set forth in claim 1 wherein the plastisol resin composition contains at least about 4 parts by weight of the stabilizing agent for about every parts by weight of the vinyl chloride-containing resin.

10. The composition set forth in claim 1 wherein the plastisol resin composition contains at least about 0.5 part by weight of the stabilizing agent for about every 150 parts by weight of the vinyl chloride-containing resin.

11. A resin composition comprising the fused plastisol resin composition of claim 1.

12. A resin composition comprising the fused plastisol resin composition of claim 2.

13. A resin composition comprising the fused plastisol resin composition of claim 4.

14. A resin composition comprising the fused plastisol resin composition of claim 5.

15. A resin composition comprising the fused plastisol resin composition of claim 6.

16. A resin composition comprising the fused plastisol resin composition of claim 7.

17. As a new composition of matter, a plastisol resin composition free of stearates and inorganic peroxides and having a stabilizer, which consists essentially of a nonstearate plasticizer, a vinyl chloride resin from the group consisting of polyvinyl chloride and vinyl chloride copolymers, said plastisol resin composition containing at least about 6 parts by weight of sodium oxalate for about every 150 parts by weight of vinyl chloride resin, said plastisol resin composition being free of stearates and inorganic peroxides.

18. As a new composition of matter, a plastisol resin composition free of stearates and inorganic peroxides and having a stabilizer, which consists essentially of a nonstearate plasticizer, a vinyl chloride resin from the group consisting of polyvinyl chloride and vinyl chloride copolymers, said plastisol resin composition containing at least about 9-12 parts by weight of sodium formate for about every 150 parts by weight of vinyl chloride resin, said plastisol resin composition being free of stearates and inorganic peroxides.

References Cited in the file of this patent UNITED STATES PATENTS 2,181,478 Kligor Nov. 28, 1939 2,507,142 Chaban May 9, 1950 2,647,296 Shive Aug. 4, 1953 2,753,321 Jankens July 3, 1956 OTHER REFERENCES.

Parker et al.: Modern Plastics, February 1953, pages 129, I30, 132, 134 and 218. 

1. A PLASTISOL RESIN COMPOSITION FREE OF STEARATES AND INORGANIC PERIOXIDES AND HAVING A STABILIZER, WHICH CONRESIN FROM THE GROUP OF POLYVINYL CHLORIDE AND VINYL CHLORIDE COPOLYMERS, SAID PLASTISOL RSIN COMPOSITION CONTAINING A STABILIZING AMOUNT OF A NONSTERATE STABILIZING AGENT OF THE GROUP CONSISTING OF ALKALI METAL FORMATE, ALKALI METAL OXALATE AND ADMIXTURES THEREOF, SAID STABILIZING AGENT BEING FREE OF INORGANIC PEROXIDES. 